Corrosion of Synthetic Intermetallic Compounds and AA7075-T6 in Dilute Harrison’s Solution and Inhibition by Cerium(III) Salts

Abstract

This study addresses the behavior of an aluminum alloy and its components in conditions simulating the presence of atmospheric salts. The corrosion of synthetic intermetallic compounds (IMCs) Al2Cu, Al2CuMg, Al7Cu2Fe, MgZn2, and bulk aluminum alloy 7075-T6 was studied in dilute Harrison’s solution (DHS, 0.35 wt% (NH4)2SO4 + 0.05 wt% NaCl). For IMCs, electrochemical measurements were performed using a microcell, and a standard electrochemical cell was used to study the bulk alloy. Separately measured cathodic and anodic potentiodynamic polarization curves were recorded, and prolonged immersion was characterized using electrochemical impedance spectroscopy. Samples were characterized using scanning electron microscopy, energy-dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy. Bulk AA7075-T6 was less susceptible to corrosion in DHS than in chloride solution stemming from the beneficial presence of sulfate ions and lower chloride concentration. The susceptibility of IMCs to corrosion in DHS increased in the order Al2Cu < Al7Cu2Fe < Al2CuMg < MgZn2 due to the increased dissolution of Mg in the presence of ammonium ions. The relative nobility of IMCs was determined based on the galvanic current density. Further, the possibility of using cerium chloride, nitrate and acetate salts as corrosion inhibitors in DHS was evaluated. Ce salts acted as inhibitors for the alloy during 14 d testing, forming a Ce hydroxide layer. The degree of protection depended on the type of anion, with acetate Ce salt giving the most efficient protection. For the IMC, however, inhibition by Ce salts did not occur during short measurements in the microcell, indicating the importance of galvanic interaction with the alloy matrix in the inhibition mechanism, which was confirmed by long-term measurements of the alloy.